Erection of brickwork structures



E. G. MALTHOUSE .ERECTION OF BRICKWORK STRUCTURES Get. 7, 1947. 2,428,374

Filed Jan. 16, 1945 4 Sheets-Sheet 1 I as A E7 E?- E8 2 F I N va/v 7'0 R .81 CQQIQM'M, Wwm

Oct. 7,' 1947. E. e. MALTH OUSE 2,428,374

' 'ERECTION OF BRICKWORK STRUCTURES Filed Jan. 16, 1945 4 Sheets-Sheet 2 FIG. 5.:

Oct. 7, 1947. E. e; M-ALTHOUSE 2,423,374

' ERECTION OF BRICKWORK STRUCTURES v I 4 Sheets-Sheet 3 Filed Jan. 16, 1945 1 l Nvgivr .E. G. MALTHOUSE 2,423,374

ERECTION OF BRICKWORK STRUCTURES Filed Jan. 16, 1945 4 sheets-sheet 4 e/vTo Patented Oct. 7, 1947 ERECTION OF BRICKWORK STRUCTURES Ernest G. Malthouse, Sheffield, England Application January 16, 1945, Serial No. 573,004

In Great Britain February 24, 1944 Claims.

This invention relates to the erection of brickwork structures by the use of brickwork units of the type which are pre-formed by laying a number of the bricks on a templet or base with the brick faces destined to provide or to determine a surface of the structure in contact with the templet or [base which has ribs or other projections locating the relative positions of the bricks and determining the width of clearance between their bonding faces, the assembly being re-inforced if desired by metal rods transverse to the courses engaging registering holes or grooves in the bricks, and fluid bonding material such as cement being grouted between the bonding faces of the bricks. The principal object of the present invention is to provide improvements in the manufacture of such pre-formed units whereby they may be used to form corners of the intended structure.

Another object is to provide improvements in reinforcing wall sections comprised in a preformed brickwork corner unit whereby the unit as a Whole 'as well as its component Wall sections may be reinforced.

Another object is to preform corner units for use in the erection of brickwork structures according to the method described in my co-pending application Serial No. 534,761.

A further object is to provide a preformed double corner unit in which two wall sections extend, one from each side of a central or intermediate wall section.

Another object is to preform a brickwork corner unit comprising four wall sections and four interior corners.

Other objects will become apparent from a perusal of this specification.

According to the present invention a brickwork corner unit comprising sections of adjacent walls is pre-formed by laying bricks on a templet or base, having ribs of projections locating the relative positions of the bricks, with gaps between the bricks at one end of the courses, by reinforcing and bonding the bricks thus laid to form one wall section, by supporting the section on the end or side edge containing such gaps with bricks bounding the gaps registering between the locating ribs of a like templetor base and by laying, reinforcing and bonding bricks to form a second wall section on the templet or base with the bricks at one end of courses filling the gaps in the supporting end or side edge of the first wall section and united to the bricks bounding such gaps by the bonding material.

Longitudinal reinforcing rods, parallel to the courses, are preferably contained in grooves along the bonding faces of the bricks and embedded in the bonding material. Such longitudinal reinforcing rods may extend continuously from one wall section to the other, the rods in the first Wall section being bent to the requisite angle in the gaps between alternate courses and the bricks bounding or filling. the gaps having transverse grooves to receive the bent rods.

Although the gaps between the bricks at one end of spaced apart courses in the first, wall section may be produced in the plane of that wall section by merely not filling the smaller end spaces between the locating ribs or projections of the templet or base arranged to cause the bricks in adjacent courses to break joint by one half the length of a brick, they may be produced in the plane of the second wall section by setting on their ends bricks laid at the ends of spaced apart I courses when laying the first wall section.

In all cases one or each of the wall sections preferably extends from the corner to a stepped end which is inclined to the line of the courses in order to facilitate erection of the corner units and to enable them to be used in erecting a brickwork structure by the method described in my co-pending application Serial No. 534,761.

A double corner unit, comprising three wall sections may be pre-formed and in this case the first wall section, with the gaps at one end of alternate courses, is preferably double the thickness of a single brick and a third wall section is laid and bonded thereto in like manner to the second .but on the other side of the first section.

The pre-formed corner unit may comprise four wall sections and in this case some of the gaps at one end of courses in a central wall section of double the thickness of a single brick are left void when preforming the second and third wall sections of a double corner unit comprising bricks filling other of such gaps and the void gaps are filled by bricks of a fourth Wallsection laid on a templet or base to form a continuation of the first or central wall section.

The fourth wall section and continuation of the central one may be laid, re-inforced and bonded on a templet having a recess or pocket to receive one of the side wall sections of the double corner unit.

In all cases re-inforcing rods transverse to the courses, may engage holes in bricks of more than one wall section comprised in the corner unit.

The locating ribs or projections of the templet preferably delineate spaces slightly greater than the faces of the bricks and in pre-forming a wall may beensured.

3 section each of the bricks is brought to bear against two of the projections which bear the same relationship to the other two in each of the spaces occupied by a brick.

A templet or base on which the second wall section is laid and having ribs or projections cating the relative positions of the bricks may be combined with means for supporting the first wall section, having the gaps at one end of courses, at the desired angle with the plane in which the second wall section is laid, reinforced and bonded. Such means may comprise a bracket or the like to which the wall section to be supported is temporarily attached, conveniently against adjustv7 hating the method of pre-forming a corner unit.

Figure 4 is a'triinetrical view of the corner unit. Figure 5 is a view similar to Figure 2 illustrating aino'dification.w

Figure 6 is an enlarged and more detailed trimetrical fragmentary view or a, corner unit 7 Figure 7. is a plan of atemplet or base for use .in'theproduction of amodified formation of cor- {nr unit of which a trimetrical view isshown in Figure 8. Figure 8 is faview of 'a corner unit.

;.Fi'gure 9 is a View similar to Figure 8 illustrati'rig'lamodificationiand.Figure 10 is a trimetrical sectional vieww illustrating a modified method of laying. a w'all'section to be incorporated in a corner-unit.

Figure: templet or base for'use' in the production of another modified formation of corner unit.

f. Like, referencenumerals indicate like parts throughoutthedrawings. I ,Ihe' templet shown in Figure 1 comprises la base 2016f rectangular outline having a series of aligned buttresses"2l at each, end, At each side there is a was; 22 detachably. supported in a groove hfthelbasie and at each end walls 23 are wedged vl' ietvl'reen"the buttresses 2i "and the ends of the walls2,2..

The a'rea'fenclosedfbetween the walls 22, and 23 [is subdivided. into spaces, each corresponding ,to a brick face. which is destined to Iprovide or to determine 'afsuriace of the corner. unit, by means pf, ribs 24 projectingsfrom the upper surface of jihebase 23. These ribsil l, which may be 'interrupees, locate the relativepositio'ns of bricks laid inlthe spaces between themcausing bricks in adjacent. courses to, break 'joint with one another 11] is a trimetrical sectional view of a land they. also determine the width of clearance F betweenthe bondingfaces of the bricks. v The spaces delineated by the ribs 24. are preferably slightly greater in both dimensions of the plane from which they project than the face of anlaverage sized brick and in use each brick is intended to be. placedin a space and brought to bear against one longitudinal and one transverse rib, the two ribs thus used to gauge the'position of each brick bearing the same relationship to V thepther two ribs bounding each of the spaces in whicha brick is laid. ,In this manner'parallel positionand correct alignment of all the'bricks .,,st blocks 25 ml. the, ainer spas between the ribs 24at one end of the templet or base and,

4 as shown, will thus be situated at one end of alternate courses defined by the ribs 24. A filler stop 26 fits into a corner at the opposite end of the templet or base and its exposed side is stepped and inclined to the line of the courses as shown in Figure 1.

In using the templet for pre-forming a wall section to be incorporated in a corner unit the bricks are 'laid as described above in the spaces between the locating ribs 24, re-inforcing rods 2? (indicated in chain lines in Figure 1) are threaded through registering holes 28 (Figure 6) in the bricks at any desired intervals and may engage any desired number of courses. One or both of the walls 22 may be slotted as shown at 28A to facilitate insertion of the re-inforcing rods 2?.

Longitudinal re-inforcing rods 29 may be laid between courses, conveniently along grooves in the bricks as shown at 3B in Figure 6, these longitudinal reinforcing rods being bent at right angles to thetemplet or base 28 where they emerge from therbricks at the sides of the stop block s.

Fluidbonding material such as cement, which is preferably mixed with sufilcient water to be rather in the nature of a liquid than a paste is 'g'routed. onto the re inforoed assembly of bricks in the templet so as to fill the bonding spaces determined by the ribs 24 aswell as the holes 28 and grooves in some of which the re-inforcing rodsfZl and 29 are disposed.

Surplus bonding material is removed before it has completely set by means of a scraper which may be supported on the walls 22, these walls being preferably of such height as to leave a layer of the bonding material covering the upper faces of the bricks in the templet. v The stop blocks 25 andthe filler-stop 26 function primarily to confine this bonding material to the area occupied by the bricks laid between the ribs 24 and the faces of the stops against which bricks abut. are of such material (preferably wood) or areso treated that the bonde d brickwork unit will not be firmly attachedthereto A further function performed bythestop blocks and fillerstop is to delineate the area to be filled with bricks whilst thestop blocks 25 ensure the production of gaps 3| between the bricks at one end of alternate courses as clearly illustrated in Figure 2 which shows diagrammatically, omitting the re-inforcing rods 21 and 29, holes 28 and grooves 30, a wall section 32 pro-formed in the templet of Figure 1. e

H This wall section, thus pre-formed is supported on the end or side edge containing the gaps 3| on the templet illustrated in Figure 3. This templet is similar to the one shown in Figure 1, having the buttresses 2 I atone end, the side walls 22,1an end wall 23 wedged against the buttresses Hand a fi ller-stop 26 in the corner between one of theside walls 22 and the end wall 23. I

A At the desired distance 'from the end wall 23, overned by the longest course in the wall section 32 a bracket or wall 33, which may have locating ribs similarto those of -the templet of Figure 1,

' extendsifrom the baSei'ZO' of the templet and is secured at'that angle thereto which is desired the brickworkcorner'unit by means of a buttressl,3 i,,both the bracket 33 and the buttress 34 preferably, engaging'grooves in the base 20. The prefformed wall section 32 is clamped against the. bracket 3,3,byan des'ired means such as the bands 35 tightened around the wall section 32 and bracket 33 bythe wedges 36. V

v Ifdesired adjustablefbolt s such as the one indicated at 33A may be fitted to the bracket 33 to provide contact points for the wall section 32 to bear against and to assist in trueing that section at the desired angle to the base 20.

The base 2|! of the templet shown in Figure 3 between the bracket32 and the end wall 23 is subdivided by locating ribs 24 similar to those shown in Figure 1 and when the section 32 is supported against the bracket 33 the bricks bounding the gaps 3| are in contact with a line of the transverse ribs 24. Bricks to provide a second wall section 37 of the corner unit are then laid on the templet between its locating ribs between the wall section 32 and the corner fillerstop- 26. In doing this alternate bricks adjoining the wall section 32 are inserted in the gaps 3| of the wall section 32 and the bricks between them abut towards, but are spaced apart from, those of the wall section 32 which separate the gaps 3| by the transverse locating ribs.

I As the wall section 3'! is thus being laid it is re-inforced and after being laid it is bonded in a similar manner to that described with reference to the formation of the wall section 32, a, batten or the like 38 preferably being laid at the base of the bracket 33 to help to confine the bonding material to the area covered by the bricks.

When the longitudinal re-inforcing rods 29 have been incorporated in the wall section 32 the grooves 39 of those bricks which bound or are inserted in the gaps 3| have transverse branches 36A to receive the bent portions of the rods 29 as clearly shown in Figure 6.

After the bonding material has set, the clamps 35, 36 are detached and the complete corner unit,

'shown'diagrammatically in Figure 4, may then be removed, transported to the building site and erected to form part of a brickwork structure. Such erection is preferably effected as described 'inmy co-pending application Serial No. 534,761

corner units being laid with their inclined stepped sides uppermost to be complementary to inverted wall section units having like stepped inclined ends.

If desired both wall sections and thus the complete corner unit may be pre-formed on the one templet, but it is generally preferred to use two such as are illustrated to avoid the necessity of changing the position of the corner filler stop 25 when laying the second wall section 31 in order that the brick faces laid on the templet shall be on the outer sides of both wall sections.

The gaps 3| in the wall section 32 are in the plane of that wall section. If desired they may be produced in the plane of the second wall section 31, as shown in Figure 5, by dispensing with the stop blocks 25 and laying the bricks 38 of Figure 5 on their ends in the spaces occupied by the stop blocks 25 in Figure 1.

As illustrated in Figures '7 and 8 the present invention may be applied to produce a double corner unit comprising a central wall section 39 with two other wall sections 49 and 4| united thereto and extending respectively from the two sides of the central wall section 39.

The central wall section 39 with the gaps at one end of alternate courses is double the thickness of a single brick and may be pre-formed in a templet of sufiicient depth but otherwise conforming to that of Figure 1 by first laying the wall section 32 as previously described and then superimposing thereon a second layer, the bricks of the upper layer being separated from those of the lower layer by loose ribs or distance pieces to provide clearance for the bonding material, as described in my copending application Serial No.

534,761 filed May 9, 1944. After the re-inforceol double wall section has been completed by the setting of the bonding material it is supported inthe templet of Figure 7 on the bricks 42 which bound the gaps 3| and the two wall sections 40 and M are then laid, re-inforced and bonded on the templet, one on each side of the double wall section with alternate bricks of the two wall sections Ml and 4| adjoining the double wall section abutting towards one another in the gaps between the bricks t2 as clearly shown in Figure '7. Thus each of the wall sections t0 and 4r| is laid, re-inforced and bonded to the central wall section 32 in the same manner as the wall section 31 of the corner unit illustrated in Figure 4. One or more of the longitudinal re-inforcing rods 29 may extend continuously in the two side wall sections so and 4H and others may extend from the central wall section 39 into one or the other of the two side wall sections.

In the double corner unit of Figure 8 all the bricks in the central wall section 39 are stretchers but if desired the double wall section may comprise both stretchers 43 and headers 44 as illustrated in the central wall section 45 of Figure 9. Such a double thickness wall section may be pre-formed in the templet diagrammatically illustrated in Figure 10, the locating ribs 46 of which are disposed to indicate how the bricks are to be laid, the stretchers 43 of the second layer being separated from those of the lower layer by loose ribs or distance pieces ll to provide clearance for the bonding material." The bricks would be suitably grooved and perforated for reception of the desired re-inforcing rods.

In order to ensure to production of the desired gaps between the bricks at one end of alternate courses of the double wall section the templet of Figure 1G is provided with stop blocks 38 functioning similarly to the stop blocks 25 ofFigure 1 but of double the depth.

. If desired, stop blocks such as 25, of a single brick thickness, may be used and in this case headers of the second layer may be laid on the stop blocks thus producing one series of the gaps 3| in the plane of the first layer and a second series of the. gaps in the plane of one of the wall sections 40 or 4|,

After the double wall section has been preformed in the templet of Figure 10 the corner unit may be completed in the templet of Figure '7 as described with reference to the corner unit of Figure 8.

The present invention may be applied to produce a pre-formed corner unit comprising four,

wall sections and four interior corners by con tinuing a central wall section such as 45 on the other side of the two flanking wall sections 49 and 4|.

For this purpose additional gaps are preferably produced at the end of the courses when preforming the central wall section 55 and these gaps or some of those provided for the wall sections 45 and 4| are left void, conveniently by the aid of appropriately disposed stop blocks such as 25 or 58 when pre-forrning a double corner unit such as illustrated in Figure 9. The bonded and re-inforced double corner unit is then supported ra se;

3 sen-sing the'idouble edrnerunitare njneu'with ks-cr the -Wall'sebtioh "S'UWh'lby the 1on1 wa r' ec'uqnsnay be' ,int'e'1locked. A brickof the fourth iva'1l"'s"ection"50' has been emitted tofshow anger the Void gaps 31' in mewauscticn "4 5 and to illustrateThow the interlocking of the Wall S'c'tiOhEiB with the remain er 'of thefcoiner unit is"e'fiect'ed. Likewise the filler-stop has been "omitted to show the locating rib'sflfi for the Wall ecti'dhiifl. s

"Whether tireeorfierunitcomprises the two'wan seduces s'za'nue'l the thfe'e'W'all' "sections 40, M

fand 39 or ta-"44 and 45hr the 'four wan sections 11034-1145 and 5!! sneer the transverse re-i'nforcing rods preferably engages holes in bricks compriseu'in both 'wall sections of each corner as "shown forexainple 'inFi'gure fi'where the re-inforcing IOd' 27A is common to'ibricks in both the Wall section 32 and theifiall'sectionl'l.

1. The method 'o'f"bu'ilding a masonry corner structure, which comprises the steps of, laying b'ricksena horizontal 'giiide'surfa'ceto form a wan Section, leaving gaps between the bricks at these tan'sebtibn; bo'nding the bricks 'of said'wall section, up-ending said section so that it rests upon ,ahbii z'dntal guide S iflfac Oh the edge having the "gaps therein, and laying and bonding bricks on said "surface to 'forfn' a second wall section the ridbricks'of certain alternatec'oursesof said'sec- Q'fid "section'fitting into the gaps of said first sec- 'tion' and bonded thereto. v I

2. The method "of huilding a masonry corner "structure, which comprises'the steps of laying bricks on a horizontal guide surface to form a Wall section, leaving'gaps between the bricks'at the'nds ofalternate courses at one edge of said Well section, reinforcing and bonding the bricks of said wall section, allowing the bond to set, upending said section so that it rests upon a hori- "zontal guide surface on the edge having the gaps therein, and laying, reinforcing, and. bonding bricks on said surface to form a second wall section, the end bricks of certain alternate courses or said second section fittinginto the g'apso'f said first section and bonded thereto.

v 3. The method of building a masonry corner structure, which comprises the steps of laying bricks on a horizontal guide surface to forin a "ii/all section, leaving gaps between the bricks "at the ends of alternate courses at one edge'of 'said wall section, j embedding angular reinforcing elements in said'sec'tion with portions thereof extending at'right angles thereto bonding thebricks "offsaid wall section, up-ending said section "so that it rests upon a horizontal guide surface on the edge having the gaps therein, and laying and Bonding bricks on said'surface toform a second Wallsection, the end bricks of certain alternate hetweenthe'brick's at "the e'nds of alternate courses aftl'one edge of said waltsection, bonding the bricks of said wall section, upee'nding said section so that-it rests u o a horizontal guide surface onthe edge hain'ng the:'gaps therein, and'laying "of alternat courses at 'oneedge of said 8 15nd wan stance witha steeped edgegthe end "bricks ercertsm'elternstetenses of said seems section fitting into nregats'or saidfirst section and" hohdedth efeto. v

5.' The method of building "a "masonry double termite-satire, 'irhich comprises the steps of laying bricks "on a horizontal "guide surface to "fbfrin avi all'sction, leaving gapslo'etween the end "hricksof alternate; courses at one end of said sectidnfihonding thehricks or the wall section, upe'ndifig' ii -section 'so'that it rests upon a horiiiontalfguide senate on the edge having the gaps tr1ereii1; and then laying'hriks onsaid surface to farmftwo so-p anar tan "sections, fitting end l'or ok'snffcertain alternate courses of said sections into the gaps of the first section, and bondmetasta is-end sections together. U

6. The of building -a masonry-double vcorner s't'ructure,fwhich conipri'ses the steps of laying tricks on a horizontal guidesurface to form 'av vallsection of double the Width of a single brick. leaving gaps between the end bricks of alternate courses: at oneend of said section,-bonding the bricks of' the Wall section,up-ending said section sothat it rests upon a horizontal guide surface on the edge having the gaps therein, and then 'layingbl icks on saidsurface to form two coplanar Wall sections of the width of' a single bric fitting end bricks of CertainaIternate courses of said sections intothe gaps of the first'section, and bonding the b'ricks and sections together.

f1. Themethod ofbuilding a masonry structure comprising a preformed corner unit consistingof four-wall sections abutting to provide four interior corners, which oomprises the-steps of laying and bonding bricks on a substantially hori- {zontalguide-surfa-ce omitting certain end bricks (qt-certain courses at the edge of said section, up- "ending said section so that it rests upon a substantially horizontalgguide surface on the edge h'aving the gaps therein, laying-two co-planar flanking wall sections on said surface, fitting end bricks of certain courses of said two flanking sections into certain of: the gaps of said first arr ed section, bonding the; bricks and sections "together, again resting said first 'named section on a substantially horizontal surface; so that the two flanking sections extend respectivelyupward- -ly and downwardly therefrom, providing another substantially-horizontal surface co-planar with saidfirst-namedsurface on the opposite side of said flanking sections from-said first named sectionylayingbricks on'said final surface 'to form the-fourth wall section, fitting certain end bricks of said-final sectiondntogaps left in'one "of the other sections.

8. A templet for-use inprep'aring a brickwork corner unit "comprising four Wall sedtions; said te'rnplet-comprisinga horizontal table having an intermediate vertical slot therein, the surface of the table upo one side of-the slot adapted-to "support a previous -iais up wan 'sebtion, the not adapted to contain addwnwardly pro] eeting rectiliriear wall section connected to said first named wall "section, and the surface "upon the opposite "side ofsaid slot being'pr'ovidedwith guide Dro- "jections"for locating' the respective positions or b'ricks hing "laid'upin'to still another wall section b'lng'interlocked with the first two sectin's. U s

f .EA ternpleti for use in preparing a brickwork icjorner uriitfsjaid ternplet comprising a horizontal tat a,; bracket projecting from the plane :of tfieftable;"and'ineans' to clamp a prev o n "andbonding'bricksonsaid surfacetoforma sed t y-1nd up wall section against one face ofth' 9 bracket, the surface of the table next that face of the bracket being provided with guide projections for locating the respective positions of bricks being laid up into a further wall section being interlocked with the first wall sections.

10. A templet for use in preparing a brickwork corner unit, said templet comprising a horizontal table, a bracket projecting from the plane of the table, adjustable bolts in the bracket, and means comprising bands surrounding the bracket and adapted for clamping a previously laid up wall section against contact points provided by the adjustable bolts, the surface of the table next that face of the bracket being provided with guide projections for locating the respective positions of bricks being laid up into a, fur- 10 Number 10 ther wall section being interlocked with the first wall sections.

ERNEST G. MALTHOUSE.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS 

